Method of manufacturing catheter and catheter manufactured by the method

ABSTRACT

A method of producing a catheter includes a step of arranging a lead wire in the lumen of a thermoplastic outer-layer tube such that the lead wire extends in the longitudinal direction of the outer-layer tube; a step of exposing one end of the lead wire out of an opening of the outer-layer tube; a step of joining the one end of the lead wire exposed out of the opening with the inner wall of a ring electrode; a step of covering the opening of the outer-layer tube with the ring electrode; an step of inserting a thermoplastic inner-layer tube in the lumen of the outer-layer tube; and an integrating step of heating the outer-layer tube and the inner-layer tube to integrate the outer-layer and the inner-layer tubes to form an electrode tip such that the lead wire is interlaminarly embedded and fixed between the outer-layer and the inner-layer tubes.

TECHNICAL FIELD

This disclosure relates to a method of producing a catheter having anelectrode tip at the front end of the catheter, and to a catheterproduced using the method.

BACKGROUND

Catheter ablation is a method of treating arrhythmia, in which method,an ablation catheter is inserted in the heart chamber, and the cardiacmuscle tissue is cauterized with an electrode attached to the distal endside of the catheter. In recent years, there has been development ofsuch an ablation catheter with a balloon as cauterizes the cardiacmuscle tissue such that the balloon attached to the distal end side ofthe catheter is transcutaneously introduced into the inferior vena cava,brought from the right atrium of the heart up to the left atrium via theatrial septum, inflated in the left atrium, and heated with ahigh-frequency current applied to an electrode inside the balloon.

In respect of treatment with use of an ablation catheter with a balloon,WO 2011/155424 discloses an ablation catheter with a balloon, in whichthe ablation catheter additionally has an electrophysiologicalexamination function to verify the determination of a cauterization siteand the treatment effect.

There is a widely known method in which a temperature measurementelectrode is fixed at the front end of a catheter, and lead wires joinedwith the measurement electrode are wired to the proximal end. A knownmethod of decreasing the risk of breakage of many lead wires wired tothe measurement electrode includes use of a catheter with an electrode,the catheter having different lead wires inserted and wired in differentlumens. In respect of this catheter with an electrode, JP 2009-268696 Adiscloses a method of fixing the electrode, in which method an adhesiveis applied to the inner periphery of the measurement electrode, which isthus fixed at or around the distal end of the catheter.

In addition, another method is disclosed (JP 2013-533065 A), in whichmethod lead wires are wound in spiral form, and arranged between thelayers of a multilayered tube.

However, such a method that involves the attachment of a measurementelectrode to the front end of a catheter as described in WO '424 and JP'696 is not sufficient to decrease the risk related to the disconnectionof the connection portion between the measurement electrode and one endof the lead wire, thus posing the possibility of occurrence of aproblem, for example, in that the adhesive is protruded or insufficient.

Another method involves arranging the lead wires of a measurementelectrode such that the lead wires are spirally wound around a tube, andthat the outside of the resulting piece is further covered with leadwires. Such a method poses a problem in that the production method iscomplicated, and a problem with insulation between the plurality of leadwires.

In view of this, there is a need to provide the following: a method ofproducing a catheter that makes it possible to decrease the risk ofdetachment of the lead wires from the electrode and the risk of breakageof the lead wires; and a catheter produced using the method.

SUMMARY

We thus provide (1) to (7):

(1) A method of producing a catheter, including: an arranging step (1)of arranging a lead wire in the lumen of a thermoplastic outer-layertube such that the lead wire extends in the longitudinal direction ofthe outer-layer tube; an exposing step of exposing one end of the leadwire out of an opening of the outer-layer tube; a joining step (1) ofelectrically joining the one end of the lead wire exposed out of theopening with the inner wall of a ring electrode; a covering step ofcovering the opening of the outer-layer tube with the ring electrode; aninserting step of inserting a thermoplastic inner-layer tube in thelumen of the outer-layer tube; and an integrating step of heating theouter-layer tube and the inner-layer tube to integrate the outer-layertube and the inner-layer tube to form an electrode tip such that thelead wire is interlaminarly embedded and fixed between the outer-layertube and the inner-layer tube.(2) The producing method according to (1), further including: anarranging step (2) of arranging a second lead wire in the lumen of theouter-layer tube such that the second lead wire extends in thelongitudinal direction of the outer-layer tube, and is not in contactwith the first lead wire; and a joining step (2) of joining one end ofthe second lead wire exposed out of the opening with the inner wall of asecond ring electrode.(3) The producing method according to (1) or (2), wherein, in theintegrating step, the outer-layer tube is covered with a heat-shrinkabletube, and heated while a compression load is applied between the frontend side and back end side of the inner-layer tube to form the electrodetip.(4) The producing method according to any one of (1) to (3), wherein, inthe joining step, one resistance welding electrode is inserted into thelumen of the outer-layer tube, another resistance welding electrode isbrought in contact with the outer wall of the ring electrode, and thering electrode and the lead wire are pressed between the resistancewelding electrodes, and thus welded.(5) The producing method according to any one of (1) to (4), including;an arranging step (3) of arranging, inside the outer-layer tube, atubular member having an opening, and sandwiching the lead wire betweenthe outer-layer tube and the tubular member; and a locating step oflocating a position such that the opening of the outer-layer tubeoverlaps the opening of the tubular member.(6) The producing method according to (5), wherein, in the joining step,one end of the lead wire and the inner wall of the ring electrode arejoined, wherein the one end is exposed out of an opening formed with theopening of the outer-layer tube and the opening of the tubular memberthat are overlapped by each other in the locating step.(7) A catheter produced by the producing method according to any one of(1) to (6).

In addition, we provide (8) to (12):

(8) A method of producing a catheter, including: an arranging step (1)of arranging a lead wire in the lumen of a thermoplastic outer-layertube such that the lead wire extends in the longitudinal direction ofthe outer-layer tube; an exposing step of exposing one end of the leadwire out of an opening of the outer-layer tube; a joining step (1) ofelectrically joining the one end of the lead wire exposed out of theopening with the inner wall of a ring electrode; a covering step ofcovering the opening of the outer-layer tube with the ring electrode; aninserting step of inserting a thermoplastic inner-layer tube in thelumen of the outer-layer tube; and an integrating step of heating theouter-layer tube and the inner-layer tube to integrate the outer-layertube and the inner-layer tube to form an electrode tip such that thelead wire is interlaminarly embedded and fixed between the outer-layertube and the inner-layer tube.(9) The producing method according to (8), further including: anarranging step (2) of arranging a second lead wire in the lumen of theouter-layer tube such that the second lead wire extends in thelongitudinal direction of the outer-layer tube, and is not in contactwith the first lead wire; and a joining step (2) of joining one end ofthe second lead wire exposed out of the opening with the inner wall of asecond ring electrode.(10) The producing method according to (8) or (9), wherein, in theintegrating step, the outer-layer tube is covered with a heat-shrinkabletube, and heated while a compression load is applied between the frontend side and back end side of the inner-layer tube to form the electrodetip.(11) The producing method according to any one of (8) to (10), wherein,in the joining step, one resistance welding electrode is inserted intothe lumen of the outer-layer tube, another resistance welding electrodeis brought in contact with the outer wall of the ring electrode, and thering electrode and the lead wire are pressed between the resistancewelding electrodes, and thus welded.(12) A catheter produced by the producing method according to any one of(8) to (11).

According to our method of producing a catheter, thermoplastic tubes areintegrated such that a lead wire joined with the inner wall of a ringelectrode is embedded between the tubes forming an electrode tip, thusmaking it possible to obtain a catheter that makes it possible todecrease the risk of detachment of the electrode from the lead wire andthe risk of breakage of the lead wire.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view depicting a catheter produced by theproducing method according to an example.

FIG. 2 is a schematic view of an electrode tip in the producing methodaccording to an example.

FIG. 3 is a schematic diagram depicting a series of processes in ourmethod.

FIG. 4 illustrates an example of an integrating step in our method.

FIG. 5 illustrates an example of a joining step in our method.

FIG. 6 illustrates an example of an arranging step and a locating stepwhich involve using a tubular member in our method.

REFERENCE SIGNS LIST

-   1 catheter-   2 catheter shaft-   3 balloon-   4 electrode tip-   10 tube-   11 ring electrode-   12 lead wire-   13 inner shaft-   14 outer shaft-   15 high-frequency electrifying electrode-   16 electrode temperature sensor-   20 handle-   21 connector-   22 external electrophysiological examination device-   23 connector-   24 high-frequency generator-   30 outer-layer tube-   31 inner-layer tube-   32 opening-   33 core wire-   34 compression spring-   35 heat-shrinkable tube-   36 laserbeam-   37 fixing jig-   42 one electric resistance welding electrode-   43 another electric resistance welding electrode-   50 tubular member-   51 opening of tubular member

DETAILED DESCRIPTION

Below, preferred examples will be described in detail with reference tothe drawings, but our methods and catheters are not limited to theseaspects. In this regard, like reference signs refer to like elements,and the duplication of the same description is omitted. In addition, theratios in the drawing do not necessarily accord with the description.

Our method of producing a catheter is characterized by including: anarranging step (1) of arranging a lead wire in the lumen of athermoplastic outer-layer tube such that the lead wire extends in thelongitudinal direction of the outer-layer tube; an exposing step ofexposing one end of the lead wire out of an opening of the outer-layertube; a joining step (1) of electrically joining the one end of the leadwire exposed out of the opening with the inner wall of a ring electrode;a covering step of covering the opening of the outer-layer tube with thering electrode; an inserting step of inserting a thermoplasticinner-layer tube in the lumen of the outer-layer tube; and anintegrating step of heating the outer-layer tube and the inner-layertube to integrate the outer-layer tube and the inner-layer tube to forman electrode tip such that the lead wire is interlaminarly embedded andfixed between the outer-layer tube and the inner-layer tube.

The back end side refers to the proximal side in the longitudinaldirection of the catheter, and the front end side refers to the distalside in the longitudinal direction of the catheter.

FIG. 1 illustrates a schematic view depicting a catheter having anelectrode tip at the front end thereof and produced by our method.

In FIG. 1, a catheter 1 includes the following: a catheter shaft 2; anda balloon 3 and an electrode tip 4 that are arranged on the distal endside of the catheter shaft. The electrode tip 4 includes a tube 10, aring electrode 11, and a lead wire 12 connected to the ring electrode11.

The electrode tip 4 is arranged at and around the front end side of thecatheter shaft 2, and the lead wire connected to the ring electrodeextends toward the proximal side of the catheter shaft. The cathetershaft 2 is constituted of an inner shaft 13 and an outer shaft 14.Examples of materials of the inner shaft 13 and the outer shaft 14include, but are not limited to, fluorine polymers, polyamides,polyurethane polymers, polyimides and the like. The inner shaft 13extends through the inside of the balloon 3 up to the distal end of thecatheter 1.

The inside of the balloon 3 includes a high-frequency electrifyingelectrode 15 and an electrode temperature sensor 16. The high-frequencyelectrifying electrode 15 is arranged to be wound around the outer wallof the inner shaft 13. The lead wire 6 enters between the high-frequencyelectrifying electrode 15 and the inner shaft 13 inside the balloon 3,and is wired toward the back end side of the catheter 1.

For example, when the ring electrode 11 is used to map cardiacpotential, the electrode tip 4 including a plurality of ring electrodes11 makes it possible to measure the shape of the potential accurately.

The proximal side of the catheter shaft 2 is provided with a handle 20,a connector 21, an external electrophysiological examination device 22,a connector 23, and a high-frequency generator 24, and the end of thelead wire 12 can be connected to the external electrophysiologicalexamination device 22 via the connector 21. Additionally, when the ringelectrode 11 is used as an RF electrode, the ring electrode can beconnected to a high-frequency generator.

FIG. 2 illustrates a schematic view of an electrode tip 4 in our method.

Electrode Tip

The electrode tip 4 includes a tube 10, a ring electrode 11, and a leadwire 12 connected to the ring electrode 11. To the inner wall of thetube 10, the inner shaft of the catheter shaft is adhered. On the outerwall of the electrode tip, a ring electrode is arranged.

For good access to the inside of an atrium, the tube 10 preferably hasan outer diameter of 1 mm to 6 mm. The material to be used for the tube10 is a thermoplastic resin, more preferably polyurethane or the like,from the viewpoint of hardness in light of the safety of the operationinside an atrium.

Ring Electrode

The end of the lead wire 12 is joined with the inner wall of the ringelectrode 11, the lead wire 12 extends in an embedded manner in the tube10, and the lead wire 12 is protruded from the proximal end of the ringelectrode 11, and wired into the lumen of the catheter shaft 2.

The electrode tip 4 may have two or more ring electrodes 11. The ringelectrodes 11 arranged on the electrode tip 4 are not limited to anyparticular number, provided that the ring electrodes 11 as well as thelead wires 12 connected to the respective ring electrodes 11 arearranged to not be in electrical contact with each other.

When a plurality of ring electrodes 11 are arranged on the electrode tip4, the ring electrodes 11 are preferably arranged with a space of 0.5 mmto 3.0 mm between them.

To prevent contact during production, the lead wires 12 connected withthe respective ring electrode 11 are preferably each arranged such thatthe lead wires 12 are located the most apart from each other duringformation of the tube 10. For example, when the electrode tip 4 has tworing electrodes 11, the lead wires 12 are joined with the respectivering electrodes 11 to be opposed to each other 180° around the centralaxis of the tube 10, and embedded inside the tube 10.

To decrease the risk of wire breakage, the lead wire 12 and the ringelectrode 11 are preferably joined in a fixed manner using a method suchas welding or soldering. When welding is used, resistance welding andlaser welding are preferable.

This electrode tip 4 can be used to treat, for example, arrhythmia suchas atrial fibrillation, and thus, can be attached to the front end ofthe catheter. Examples of catheters for which the electrode tip is usedinclude balloon catheters, ablation catheters, ablation catheters with aballoon and the like, and the electrode tip is preferably used for anablation catheter with a balloon.

Lead Wire

The lead wire 12 is not limited to any particular diameter, and the leadwire 12 preferably has a diameter of 0.05 mm to 0.30 mm from theviewpoint of decreasing the risk of wire breakage during wiring and fromthe viewpoint of making it easy to secure a space for wiring to theelectrode tip or the catheter shaft portion.

A material to be preferably used for the lead wire is phosphor bronze,copper or the like. In addition, a material to be preferably used forthe ring electrode is platinum, platinum, stainless steel, gold, silver,copper, an alloy thereof or the like, considering contact with anorganism.

FIG. 3 illustrates a schematic diagram of a series of processes in amethod of producing an electrode tip in a catheter having an electrodetip according to an example.

Arranging Step of Arranging Lead Wire in Lumen of ThermoplasticOuter-Layer Tube Such that Lead Wire Extends in Longitudinal Directionof Outer-Layer Tube

An outer-layer tube 30 containing a thermoplastic resin and a lead wire12 are provided. The lead wire 12 is arranged in the lumen of thethermoplastic outer-layer tube 30 such that the lead wire extends inparallel with the longitudinal direction of the outer-layer tube 30. Inthis example, the lead wire 12 extending in parallel with thelongitudinal direction in the lumen of the outer-layer tube 30 does notneed to be strictly parallel with respect to the longitudinal directionof the outer-layer tube 30.

Specifically, this means that the lead wire 12 is not wound but isextended from the distal end of the outer-layer tube 30 toward theproximal end, and this meaning encompasses examples where the lead wire12 is slightly loosened or sagged, and thus is not strictlyparallelized.

Exposing Step of Exposing One End of Lead Wire Out of Opening ofOuter-Layer Tube

Next, an opening 32 is formed in the outer wall of the outer-layer tube30, out of which opening, the lead wire 12 stripped of an insulatingcoating is exposed. The opening 32 may have an arbitrary size, butshould have a size that can be covered with the ring electrode 11.

When a plurality of ring electrodes 11 are arranged in the electrode tip4, the corresponding plurality of lead wires 12 are arranged, and thus,the openings 32 the number of which corresponds to that of the leadwires 12 are formed in the outer-layer tube 30. In addition, theopenings 32 are formed at the positions spaced from each other in thelongitudinal direction of the outer-layer tube 30 to expose the leadwires 12 at the respective positions of the ring electrodes 11corresponding to the openings.

Joining Step of Electrically Joining One End of Lead Wire Exposed out ofOpening with Inner Wall of Ring Electrode

Next, one end of the lead wire 12 and the inner wall of the ringelectrode are electrically joined using a method such as welding orsoldering. The electrical joining is performed such that the one end ofthe lead wire 12 comes in contact with the inner wall of the ringelectrode 11.

The electrical joining refers to joining the lead wire and the ringelectrode so that electricity can be conducted between the lead wire andthe ring electrode.

FIG. 3 illustrates an example of a joining step.

The lead wire 12 is extended in parallel with the longitudinal directionof the outer-layer tube 30 in the lumen of the outer-layer tube 30, andthe outer-layer tube 30 is covered with the ring electrode 11. Next, oneelectric resistance welding electrode 42 is inserted into the lumen ofthe outer-layer tube 30, and the lead wire 12 and the electricresistance welding electrode 42 are brought in contact with each other.The lead wire 12 is exposed through the opening 32 out of theouter-layer tube 30. The one end of the lead wire 12 exposed is broughtin contact with the inner wall of the ring electrode 11.

Another resistance welding electrode 43 is brought in contact with theouter wall of the ring electrode 11. The ring electrode 11 and the leadwire 12 are pressed between the electrodes, and electrically joined bywelding.

The resistance welding electrode is not limited to a particularmaterial, and a material to be used is copper, chromium copper, tungstenor the like. It is preferable that the shape of the front end of the oneresistance welding electrode 42 is smaller than the opening 32, and isshaped to conform to the inner diametric shape of the tube so that thelead wire 12 can be exposed out of the outer-layer tube 30 to be broughtin contact with the inner wall of the ring electrode 11. For example,the shape is preferably arc-shaped if the outer-layer tube 30 iscylindrical.

This method makes it possible that the lead wire 12 is electricallyjoined with the inner wall of the ring electrode 11 in a reliable mannerand in a short time. That method also makes it possible that the ringelectrode 11 and the lead wire 12 are electrically joined withoutchanging the state where the opening 32 of the outer-layer tube 30 iscovered with the ring electrode 11. This involves neither unnecessarilydrawing the lead wire 12 out nor drawing the lead wire back, accordinglymakes it possible to decrease the risk of wire breakage, and thus, ispreferable, compared to a conventional method in which the lead wire 12is much drawn out of the opening 32, and electrically joined with theinner wall of the ring electrode 11, and the excessive portion of thelead wire 12 is drawn back through the opening while the outer-layertube 30 is covered with the ring electrode 11.

Covering Step of Covering Opening of Outer-Layer Tube with RingElectrode

The ring electrode 11 is caused to cover the outer-layer tube 30 tocover the opening 32. The ring electrode is allowed to cover the openingbefore being electrically joined with the lead wire as above-mentioned,and then be electrically joined at the position of covering, or may beelectrically joined at a position deviated from the opening, followed bycovering the opening with the ring electrode. Thus, arranging the ringelectrode 11 at the position at which to cover the opening 32 of theouter-layer tube 30 makes it possible to prevent the lead wire 12 frombeing exposed to the outside.

Inserting Step of Inserting Inner-Layer Tube in Lumen of Outer-LayerTube

An inner-layer tube 31 containing a thermoplastic resin is provided, andthe inner-layer tube 31 is inserted into the lumen of the outer-layertube 30. When this is done, the inner-layer tube 31 is inserted suchthat the lead wire 12 is inserted interlaminarly between the outer-layertube 30 and the inner-layer tube 31, maintaining the arrangement formextended in the longitudinal direction of the tubes. The inner diameterof the outer-layer tube 30 is larger than the outer diameter of theinner-layer tube 31, and thus, the inner-layer tube 31 can be insertedinto the lumen of the outer-layer tube 30. In this regard, the step ofinserting the inner-layer tube 31 into the lumen of the outer-layer tube30 may be followed by a step of arranging the lead wire 12 in the lumenof the outer-layer tube 30 to extend in the longitudinal direction ofthe outer-layer tube 30. In this example, the lead wire 12 is arrangedin the lumen of the outer-layer tube 30 such that the lead wire 12 isinserted interlaminarly between the outer-layer tube 30 and theinner-layer tube 31.

Allowing the lead wire 12 to be arranged to extend in parallel with thelongitudinal direction interlaminarly between the outer-layer tube 30and the inner-layer tube 31 makes it possible to inhibit a load frombeing applied in the direction in which the lead wire 12 is separatedfrom the ring electrode 11, and thus to decrease the risk of wirebreakage of the lead wire 12 and the electrically joined portion betweenthe lead wire 12 and the ring electrode 11. Additionally, when two ormore lead wires 12 are used, arranging the lead wires as above-mentionedmakes it possible to decrease the risk of intertanglement and contactbetween the lead wires.

Integrating Step of Heating Outer-Layer Tube and Inner-Layer Tube toIntegrate Outer-Layer Tube and Inner-Layer Tube Such that Lead Wire isInterlaminarly Embedded and Fixed Between Outer-Layer Tube andInner-Layer Tube

A core wire 33 for heating the outer-layer tube 30 and the inner-layertube 31 is inserted into the lumen of the inner-layer tube 31.

The outer-layer tube 30 and the inner-layer tube 31 contains athermoplastic resin, and thus, heating the core wire 33 causes theouter-layer tube 30 and the inner-layer tube 31 to be integrated to forma tube 10. The lead wire 12 is arranged between the outer-layer tube 30and the inner-layer tube 31, and thus, the lead wire 12 isinterlaminarly embedded and fixed, extending in parallel with thelongitudinal direction between the outer-layer tube 30 and theinner-layer tube 31. As a result, the lead wire 12 is embedded and fixedto extend in parallel with the inside of the tube 10, and the ringelectrode 11 is fixed on the outer wall of the tube 10.

In the above-mentioned producing method, the outer-layer tube 30 and theinner-layer tube 31 are integrated to form the tube 10 with the leadwire 12 arranged to extend in parallel with and between the outer-layertube 30 and the inner-layer tube 31, and thus, the lead wire 12 isfixed, extending in parallel with and inside the tube 10.

This makes it possible to inhibit a load from being applied to theelectrically joined portion between the ring electrode 11 and the leadwire 12 even if the electrode tip 4 is curved during the operation ofthe catheter 1. In addition, the above-mentioned arrangement makes itless likely that the lead wire 12 is broken by twisting or moving, andthus, makes it possible to decrease the risk of wire breakage of thelead wire.

In addition, the insulating coating of the lead wire 12 is opened at andaround the joined site between the ring electrode 11 and the lead wire12, which are thus ready to be in electrical contact. When the electrodetip 4 includes a plurality of ring electrodes 11, this can pose thepossibility that a plurality of lead wires 12 come in contact with eachother during production, but, when the outer-layer tube 30 and theinner-layer tube 31 are integrated, the lead wires 12 are arranged toextend in parallel with each other, thus making it possible to preventthe lead wires 12 from coming in contact with each other, and to providereliable insulation because the tube 10 is arranged between the leadwires 12.

The above-mentioned outer-layer tube 30, inner-layer tube 31, and tube10 can be set to any thickness. In addition, the outer-layer tube 30 andthe inner-layer tube 31 are preferably composed of the samethermoplastic resin because the integrally formed tube 10 can havestable strength.

FIG. 4 illustrates a variant example of a step of heating theouter-layer tube 30 and the inner-layer tube 31 to integrate theouter-layer tube 30 and the inner-layer tube 31 such that the lead wire12 is interlaminarly embedded and fixed between the outer-layer tube 30and the inner-layer tube 31.

In the step of integrating the outer-layer tube 30 and the inner-layertube 31, a compression load is applied between the front end side andback end side of the inner-layer tube 31. One end of the outer-layertube 30 and inner-layer tube 31 is fixed with a fixing jig 37, acompression spring 34 is brought in contact with the other end, and thecompression spring 34 is fixed with a fixing jig 37 at a position thatcauses compression. This makes it easy to apply a compression load andat the same time perform heating.

Next, the ring electrode 11 and the outer wall of the outer-layer tube30 are covered with a heat-shrinkable tube 35. The heat-shrinkable tube35 having the smallest shrinkage inner diameter smaller than the outerdiameter of the ring electrode 11 can provide a sufficient shrinkageforce, and thus, is preferable.

In addition, a core wire 33 is inserted into the lumen of theinner-layer tube 31. The core wire 33, which is made of metal such asstainless steel, is heated to be adhered to the inner-layer tube 31, andthus, preferably undergoes surface-treatment or the like to have goodreleasability.

Next, a heating procedure is performed. The source of heat is preferablya laserbeam 36. The laserbeam 36 is preferably a carbon dioxide gaslaser or a semiconductor laser. Exposure to the laserbeam 36 with thecore wire 33 being rotated makes it possible to uniformly heat the wholecircumference of the outer-layer tube 30 and inner-layer tube 31 whichare being integrated. In addition, simultaneously moving the exposureposition of the laserbeam 36 makes it possible to continuously heat theouter-layer tube 30 and inner-layer tube 31 in the longitudinaldirection.

Continuously heating the outer-layer tube 30 and the inner-layer tube 31in the longitudinal direction makes it possible to prevent the lead wire12 from deviating from the arrangement of extension in the longitudinaldirection of the outer-layer tube 30 and inner-layer tube 31 which arebeing integrated. In addition, not only the ring electrode 11 is locallyheated, but also the portions that are interlaminar between theouter-layer tube 30 and the inner-layer tube 31 and are not covered withthe ring electrode 11 are heated, thus making it possible to decreasethe risk of applying an unnecessary load to the lead wires 12, and todecrease the risk of short-circuit between the lead wires 12.

The compression spring 34 applying a compression load results inexpanding the outer-layer tube 30 and the inner-layer tube 31 in theradial direction, and heating the ring electrode 11 and the outer-layertube 30 which are covered with the heat-shrinkable tube 35 results ineffectively filling up the gap between the ring electrode 11 and theouter-layer tube 30, thus obviating a difference in the level betweenthe ring electrode 11 and the outer wall of the outer-layer tube 30. Theheat-shrinkable tube 35 is not limited to any particular material, andan olefin resin material or a fluorine resin material is preferablyused. The heat-shrinkable tube 35 is detached after the integrationprocessing.

FIG. 5 illustrates an example of a joining step.

The lead wire is extended in generally parallel with the longitudinaldirection of the outer-layer tube in the lumen of the outer-layer tubesuch that the outer-layer tube is covered with the ring electrode. Next,one electric resistance welding electrode 42 is inserted into the lumenof the outer-layer tube, and brought in contact with the lead wire. Thelead wire is protruded through an opening out of the outer periphery ofthe outer-layer tube, and the lead wire is brought in contact with theinner periphery of the ring-shaped electrode.

Another electric resistance welding electrode 43 is brought in contactwith the outer periphery of the ring-shaped electrode, the parts betweenthe welding electrodes are electrically joined by electric resistancewelding while being pressed.

The resistance welding electrode is not limited to any particularmaterial, and a material to be used is copper, chromium copper, tungstenor the like. The shape of the front end of the resistance weldingelectrode is preferably an arc-shaped surface smaller than the openingto enable the lead wire to protrude through the opening and be broughtin contact with the inner periphery of the ring electrode.

FIG. 6 illustrates an example of an arranging step and a locating stepwhich involve using a tubular member.

Arranging Step of Arranging, Inside Outer-Layer Tube, Tubular MemberHaving Opening, and Sandwiching Lead Wire Between Outer-Layer Tube andTubular Member

To prevent each arranging step from taking a long time, a tubular member50 having an opening 51 is provided, and the tubular member 50 isfurther arranged inside from the lead wire 12 arranged to extend inparallel with the longitudinal direction in the lumen of theabove-mentioned outer-layer tube 30. Thus, both arranging, inside theouter-layer tube 30, the tubular member 50 having the opening 51, andsandwiching the lead wire 12 between the outer-layer tube 30 and thetubular member 50 allow the lead wire 12 and the outer-layer tube 30 tobe supported by the tubular member 50. To be supported means that thestate where the outer-layer tube 30 and the lead wire 12 are arranged atthe respective positions is maintained under no external force.Furthermore, even when an external force is applied to the outer-layertube 30 and the lead wire 12 in the arranging steps (1) to (3), thetubular member 50 existing inside from the outer-layer tube 30 makes itpossible that the shape of the outer-layer tube 30 is maintained, andthat the position of the lead wire 12 is prevented from deviating.

Locating Step of Locating Position Such that Opening of Outer-Layer TubeOverlaps Opening of Tubular Member

Next, the opening 32 of the outer-layer tube 30 and the opening 51 ofthe tubular member 50 are located to overlap. This makes it possiblethat, in the joining step of electrically joining one end of the leadwire exposed out of an opening with the inner wall of the ringelectrode, the lead wire 12 is exposed out of the outer-layer tube 30through the opening made by the overlapping of the opening of theouter-layer tube 30 and the opening 51 of the tubular member 50 when theone electric resistance welding electrode 42 is inserted into the lumenof the tubular member 50 and the outer-layer tube 30 to bring the leadwire 12 in contact with the electric resistance welding electrode 42.This makes it possible that the front end of the one electric resistancewelding electrode 42 passes through the opening 51 to come in contactwith the lead wire 12 without coming in contact with the tubular member50. Then, the lead wire 12 can be protruded through the opening 32 outof the outer periphery of the outer-layer tube 30, and the lead wire canbe brought in contact with the inner periphery of the ring-shapedelectrode.

That is, a method of producing a catheter, including; an arranging step(3) of arranging, inside the outer-layer tube, a tubular member havingan opening, and sandwiching the lead wire between the outer-layer tubeand the tubular member; and a locating step of locating the positionsuch that the opening of the outer-layer tube overlaps the opening oftubular member, is illustrated as one aspect of a method of producing acatheter. These arranging step (3) and locating step need only to beperformed after the arranging step of arranging the lead wire in thelumen of the thermoplastic outer-layer tube to extend the lead wire inthe longitudinal direction of the outer-layer tube, and before theexposing step of exposing one end of the lead wire out of the opening ofthe outer-layer tube.

The opening 51 of the tubular member 50 is not limited to any particularshape, and needs only to be formed such that the opening of theouter-layer tube 30 and the opening 51 of the tubular member 50 overlapwhen the tubular member 50 is arranged inside the outer-layer tube 30.The opening 51 preferably has the same shape as the opening 32 of theouter-layer tube 30.

The outer diameter of the tubular member 50 needs only to be in therange that makes it possible to sandwich the lead wire 12 between theouter-layer tube 30 and the tubular member 50, and further to supportthe lead wire and the outer-layer tube. The outer diameter R of thetubular member 50 is preferably in the range of 0.9×r≤R≤1.1×r, whereinthe inner diameter of the outer-layer tube is D1, the diameter of thelead wire 12 is D2, and D1−(D2×2)=r.

In addition, the inner diameter of the tubular member 50 is not limitedto any particular value, and needs only to be such that the one electricresistance welding electrode 42 does not come in contact with thetubular member 50 when the one electric resistance welding electrode one42 is inserted into the lumen of the tubular member 50 in the joiningstep.

The tubular member 50 is not limited to any particular material, and ispreferably made of metal or resin from the viewpoint of ease ofproduction and ease of handling. In addition, it is more preferable thatthe material is insulating to eliminate the possibility that electricityruns in the tubular member 50 to generate a welding defect duringelectric resistance welding in the joining step. Furthermore, even whenthe material is non-insulating, the material needs only to beelectrically independent.

Using this method makes it possible to electrically join the lead wirewith the inner periphery of the ring electrode in a reliable manner andin a short time, and makes it possible to electrically join the ringelectrode with the lead wire with the outer-layer tube covered with thering electrode. This involves neither unnecessarily drawing the leadwire out nor drawing the lead wire back, accordingly makes it possibleto decrease the risk of wire breakage, and thus, is preferable, comparedwith a conventional method in which the lead wire is much drawn out ofthe opening, and electrically joined with the inner periphery of thering electrode, and the excessive portion of the lead wire is drawn backthrough the opening while the outer-layer tube is covered with the ringelectrode. In addition, electrical joining with an adhesive makes itdifficult for the adhesive to effectively fill up a gap generatedbetween the inner periphery of the ring electrode and the opening, andis complicated from the viewpoint of management of a leaky orinsufficient adhesive. Accordingly, the above-mentioned method ispreferable.

EXAMPLES Example 1

A medical tubing device was used to produce a polyurethane-madeouter-layer tube having an outer diameter of 3.6 mm, an inner diameterof 3.4 mm, and a length of 10 mm. In this outer-layer tube, two openingswere made, each having a length of 0.9 mm in the longitudinal directionof the tube and a width of 1.2 mm. The first opening was formed at aposition 3.5 mm apart from an end of the outer-layer tube, and thesecond opening was formed at a position that is 180° opposed to thefirst opening in the outer wall of the outer-layer tube, and is apartfrom 6.5 mm from the end of the outer-layer tube.

In addition, one end of a phosphor bronze wire covered with aninsulating polyurethane coating and having a diameter of 0.1 mm wasstripped of the insulating coating, and inserted into the lumen of theouter-layer tube.

The phosphor bronze wire stripped of the insulating coating was exposedout the opening of the outer-layer tube, and the phosphor bronze wirewas extended in parallel with the longitudinal direction of theouter-layer tube.

Next, the outer-layer tube was covered with a platiniridium-made ringelectrode having an outer diameter of 3.8 mm, an inner diameter of 3.6mm, and a width of 1.5 mm such that the ring electrode was arranged at aposition at which to cover the opening.

Next, a chromium-copper-made electric resistance welding electrode thefront end of which was 0.5 mm square was inserted into the lumen of theouter-layer tube, and brought in contact with the lead wire. Achromium-copper-made resistance welding electrode the width of which was1.5 mm and the front end of which had a semi-circular arc shapeconforming to the circular arc shape of the ring electrode was broughtin contact with the outer wall of the ring electrode. The parts betweenthe electrodes were electrified under a pressure of 15 N to be thusjoined by resistance welding.

Next, an inner-layer tube made of the same material as the outer-layertube and having an outer diameter of 3.4 mm, an inner diameter of 1.7mm, and a length of 15 mm was inserted into the lumen of the outer-layertube, and a phosphor bronze wire was inserted interlaminarly between theouter-layer tube and the inner-layer tube and extended in thelongitudinal direction. When this was done, the two phosphor bronzewires were arranged to be 180° opposed to each other between the layers.

The multilayered tube made in this manner was covered with a fluorineresin-made heat-shrinkable tube having an inner diameter of 4.5 mmbefore shrinkage, a thickness of 0.2 mm after shrinkage, and a length of10 mm.

Furthermore, a stainless steel-made core member was inserted into thelumen of the inner-layer tube, one end of the inner-layer tube wasfixed, a compression coil spring having a spring constant of 1 N/mm wasattached to the other end, and a compression load of 10 N was appliedbetween the front end side and back end side of the inner-layer tube.

Using a laser welding machine configured for a wavelength of 940 nm, thetube was rotated under a compression load and, at the same time, exposedto a laserbeam being caused to shift in the longitudinal direction ofthe tube.

The distal side of a polyamide-made inner shaft was inserted and adheredin the lumen of the electrode tip made in this manner, and the phosphorbronze wire connected to the ring electrode was wired toward theproximal side of this inner shaft.

Next, a copper wire a part of which was stripped of an insulatingcoating was provided as a high-frequency electrifying electrode, and aconstantan-made sensor wire to be used as an electrode temperaturesensor was provided. The copper wire was wound in coil form around theinner shaft such that both of these sandwiched the sensor wiretherebetween. Thus, a coil-shaped high-frequency electrifying electrodehaving a length of 13 mm and the electrode temperature sensor arrangedat the back end portion of the high-frequency electrifying electrodewere formed. The copper wire and the sensor wire were wired toward thedistal side along the inner shaft.

A polyurethane-made balloon was arranged to encompass the high-frequencyelectrifying electrode and the electrode temperature sensor that wereformed in this manner. The distal end portion of the balloon was fixedto the electrode tip by heat welding, and the proximal end portion ofthe balloon was fixed to a polyurethane-made outer shaft by heatwelding.

The proximal side of the catheter shaft had a handle, and the copperwire of the high-frequency electrifying electrode and the electrodetemperature sensor wire were connected through the handle to a connectorfor a high-frequency generator.

In addition, the phosphor bronze wire connected to the ring electrodewas also connected through the handle to a connector for measurement ofelectrical potential. Thus, a balloon catheter having the electrode tipin the Example was produced.

Example 2

Two openings each having a length of 0.9 mm in the longitudinaldirection and a width of 1.2 mm were formed in a stainless steel tubularmember having an outer diameter of 3.3 mm, an inner diameter of 2.6 mm,and a length of 12 mm such that the openings were formed to overlap therespective openings of the outer-layer tube 30. The tubular member thusformed was arranged inside from the lead wire arranged to extend inparallel with the longitudinal direction of the lumen of the outer-layertube. A balloon catheter having an electrode tip was produced in Example2 under the same conditions as in Example 1 except these conditions.

Comparative Example

Using the ring electrode and the phosphor bronze wire that weredescribed in Examples, the phosphor bronze wire stripped of aninsulating coating was brought in contact with the inner wall of thering electrode, and both of these were joined by resistance welding. Aballoon catheter having an electrode tip was produced in ComparativeExample in the same manner except that the outer-layer tube and theinner-layer tube which were described in Examples were not used, andthat the lead wire was not embedded in the tube.

Verification of how Two Phosphor Bronze Wires are Embedded andShort-Circuited

The electrode tip in each of the Examples was cut crosswiseperpendicularly to the longitudinal direction. The resultingcross-section made it possible to verify that the phosphor bronze wireswere embedded and fixed in the integrated multilayered tube, and thatthe two phosphor bronze wires were extended without contact with eachother. In addition, a resistance measurement device was used to verifythat both of them were not short-circuited.

Strength Test on Connected Portions of Phosphor Bronze Wires

With the electrode tip in Example 1, the phosphor bronze wire and thepolyurethane-made multilayered tube were pulled toward each other usinga tensile tester at a testing speed of 10 mm/min to measure the breakingstrength, with the result that the phosphor bronze wire was broken at7.2 N at a wired position other than the welded portion.

With the electrode tip in Example 2, the phosphor bronze wire and thepolyurethane-made multilayered tube were pulled toward each other usinga tensile tester at a testing speed of 10 mm/min to measure the breakingstrength, with the result that the phosphor bronze wire was broken at7.5 N at a wired position other than the welded portion.

On the other hand, with the electrode tip in Comparative Example, thering electrode and the phosphor bronze wire were pulled toward eachother using a tensile tester at a testing speed of 10 mm/min to measurethe breaking strength, with the result that the phosphor bronze wire wasbroken at 4.0 N at the welded portion.

The above-mentioned results have revealed that causing the phosphorbronze wire joined with the inner wall of the ring electrode to extendin an embedded manner in the tube in the electrode tip makes it possibleto reinforce the fixation of the phosphor bronze wire and thus to obtaina catheter that decreases the risk of wire breakage.

INDUSTRIAL APPLICABILITY

Our methods and catheters can be used, in the field of medicine, as acatheter the front end of which has an electrode tip for treating, forexample, arrhythmia such as atrial fibrillation.

1-7. (canceled)
 8. A method of producing a catheter, comprising: anarranging step of arranging a lead wire in the lumen of a thermoplasticouter-layer tube such that said lead wire extends in the longitudinaldirection of the outer-layer tube; an exposing step of exposing one endof said lead wire out of an opening of said outer-layer tube; a joiningstep of joining said one end of said lead wire exposed out of saidopening with the inner wall of a ring electrode; a covering step ofcovering said opening of said outer-layer tube with said ring electrode;an inserting step of inserting a thermoplastic inner-layer tube in thelumen of said outer-layer tube; and an integrating step of heating saidouter-layer tube and the inner-layer tube to integrate said outer-layertube and said inner-layer tube to form an electrode tip such that saidlead wire is interlaminarly embedded and fixed between said outer-layertube and said inner-layer tube.
 9. The method according to claim 8,further comprising: another arranging step of arranging a second leadwire in the lumen of said outer-layer tube such that said second leadwire extends in the longitudinal direction of said outer-layer tube, andis not in contact with the first lead wire; and another joining step ofjoining one end of said second lead wire exposed out of said openingwith the inner wall of a second ring electrode.
 10. The method accordingto claim 8, wherein, in said integrating step, said outer-layer tube iscovered with a heat-shrinkable tube, and heated while a compression loadis applied between the front end side and back end side of saidinner-layer tube to form said electrode tip.
 11. The method according toclaim 8, wherein, in said joining step, one resistance welding electrodeis inserted into the lumen of said outer-layer tube, another resistancewelding electrode is brought in contact with the outer wall of said ringelectrode, and said ring electrode and said lead wire are pressedbetween said resistance welding electrodes, and thus welded.
 12. Themethod according to claim 8, comprising: a third arranging step ofarranging, inside said outer-layer tube, a tubular member having anopening, and sandwiching said lead wire between said outer-layer tubeand said tubular member; and a locating step of locating a position suchthat the opening of said outer-layer tube overlaps said opening of saidtubular member.
 13. The method according to claim 12, wherein, in saidjoining step, one end of said lead wire and the inner wall of said ringelectrode are joined, and the one end is exposed out of an openingformed with said opening of said outer-layer tube and said opening ofsaid tubular member that are overlapped by each other in said locatingstep.
 14. A catheter produced by the method according to claim 8.